Pulverulent cleaning composition



Patented May 26, 1936 I V UNITED STATES PATENTFOFFICE 2,041,744 PULVERULENT CLEANING COMPOSITION Arthur B. Cummins, Plainfield, N. J., assignor to- Johnsville Corporation, New York, N. Y., a corporat on of New York No Drawing. Application June 13, 1932, Serial No.'617,048

Claims. (01. 87-5) This invention relates to a diatomaceous earth after the calcinaticn, but that there is not comcomposition. It pertains especially to a compoplete destruction of such structure. The result sition of matter adapted for use as a cleanser is a porous product composed of inherently hard or a polish and containing diatomaceous earth material, chiefly silica, but having a weak'struc- 5 that has been calcined in comminuted form. A ture. Such a product is widely used as a filter 5 preferred embodiment is a cleanser containing aid, as in sugar refining. diatomaceous earth calcined in comminuted The diatomaceous earth product so made will form and an emulsification agent and/or a devary somewhat in particle size, depending upon tergent. the exact method of milling or comminuting and Many common household cleansers comprise other features of the process or quality of diato- 10 an emulsification agent, such as powdered soap, maceous earth used as the raw material. In a a detergent, such as trisodium phosphate or soda typical operation there has been produced a calash, and an abrasive. Abrasives that are used in cined product containing a substantial proporconventional cleansers are of the type of feldtion, more than 5 percent, usually 10 to per- 15 spar, quartz, or pumicite, all in finely ground cent, of particles that are retained on a 325- 1 form. The scratching of surfaces to which the mesh screen in a wet screening test, and less cleanser is applied has been recognized as a disless than 2 percent retained on a 30-mesh screen advantage, and attempts have been made to prein a similar test.

pare or select an abrasive of adequate cutting or The calcined product made as described is cleansing action with a minimum of the undewhite in color, the particular shade of white 20 sired scratching action. varying somewhat with the conditions'of manu- Thus, attempts have been made to use diatomafacture and quality of diatomaceous earth used ceous earth and there has been a limited use of as the raw material, and being sometimes of a comminuted diatomaceous earth in the natural slight pink cast.

condition, in cleansers and polishes. Such earth The material so made is adapted for use in 25 has been found too soft and not sufiiciently rapid cleansers, for example. In making a cleanser, in its cutting action, for many purposes. the diatomaceous earth which has been calcined I have now discovered that certain objections in comminuted form in the presence of a flux, is

to the natural earth in comminuted form, as an mixed with an emulsification agent and/or a ingredient of cleansers, may be overcome and detergent. The mixing is suitably performed 30 products of broad utility made by the substituin a gentle manner, as in a vessel provided with tion of diatomaceous earth that has been cala horizontal agitator, whereby the diatomic cined in comminuted form, as illustrated in the structure of the calcined diatomaceous earth is following example. not destroyed, in distinction from a condition 5 Diatomaceous earth, such as high quality mathat might result from thoroughly grinding toterial from an important Lompoc, California, gether the in r i n as in a ball mill. deposit, containing over 92 percent of silica on As the emulsification agent, there is used a the dry basis, is treated by a process including small amount of powdered soap. The amount calcination, in comminuted form in the presence used is preferably in excess of 2 percent, and

of a flux, as, for example, as described in U. S. suitably 5 to 10 percent. 40 Patent 1,502,547 to Calvert, Dem and Alles. The detergent used may be trisodium phos- Thus the diatomaceous earth is first dried and phate, the proportion being suitably 5 to 30 percomminuted, that is, finely divided without decent, as, for example, 15 percent. struction of the diatomic structure, mixed with The proportion of diatomaceous earth used is a small proportion of a flux, say 5 percent of suitably to of the entire cleansing com- 45 anhydrous sodium carbonate, and then calcined position. at a temperature at which there is moderate All proportions in the specifications and also in sintering action, as, for example, at 1800 F. The the claims are expressed as percentage, by which product of the calcination is then cooled and is meant parts by weight for parts of finished 5 again comminuted in such manner as to disintemixture. 50 grate partly the clusters formed during the cal- The compositions, it will be ;noted, consist cination, without destroying the diatomic strucchiefly of the diatomaceous earth that has been ture of the product. It will be understood that calcined as described and a small proportion only there is some fracturing of individual diatoms of other ingredients. These proportions are.

55 during the comminuting process, both before and critical in making a cleaning and polishing com- 55 position, which, because of the evident efiect of the large proportion of insoluble material, is adapted for use in moistened paste form, as distinguished from a bar of soap, for instance. The latter contains only a relatively small proportion of material of the type of and a predominating proportion of soap. If it were attempted to use a composition of this latter type in powdered form, as a cleaning or polishing paste, the large proportion of soap would impart a yieldable nature to the composition and obscure the desired abrasive action of the small amount of admixed diatomaceous earth. Further, the important density-reducing efiect of the very bulky diatomaceous earth is largely lost in a soap bar or the like in which the proportion of diatomaceous earth is small and the compact soap, of necessity, fllls the voids within or between the micrcscopic particles of the said earth.

The mixture of diatomaceous earth calcined in comminuted form in the presence of a flux and the emulsification agent and/or the detergent, has several interesting properties. The mixture, as usually made, is nearly pure white. It is a pulverulent composition that has a superior polishing action, possibly explained by the weak structure of the abrasive ingredient; a porous diatomic structure, although composed of inherently hard material, may crush under the application, during use as a cleanser, or certain pressures which would cause scratching of the surface being cleaned, were it not for the crushing of the weak structure of the abrasive. Also, the porous structure permits of some absorption of dirt, greases, and the like, within the abrasive. In addition, the clenser mixture is very bulky; a typical preparation weighs not substantially more than 20 pounds per cubic foot, as compared to a weight of 33 to 78 pounds per cubic foot for a large number of conventional household cleansers. This bulkiness of my improved composition is accompanied by a decrease in the number of pounds required to clean a given area of certain surfaces. Thus, in a comparable usage, it has been found that my improved composition will clean a substantially larger area than an equal weight of a more dense cleanser. In fact, certain results indicate that the area which can be cleaned is roughly proportional to the increase in bulk of my cleanser as compared to that of certain conventional cleansers.

The utility of a cleanser having adequate cutting action or abrasive action on dirt, grease, and the like, with a minimized scratching action, should be evident. Thus, the material is satisfactory for polishing or cleaning dishes, outlery, window glass, porcelain, and woodwork. Cleansed, highly polished, and well appearing surfaces may be imparted to the article cleaned.-

Certain improvements may be made to the cleanser described above.

Thus, the mixture, after being made by the method described, may be aged, as at atmospheric or an elevated temperature. Thus the material may be warmed, suitably at a temperature not in excess of 212 F., for a short period before being filled into packages for shipment or use. This warming before packaging increases the freedom of flowing of the mixture from the package during use, as, for example, through perforations in the top of the package. It is possible that this preliminary warming may cause a partial drying of the emulsification agent or detergent, as by vaporization of a small amount of diatomaceous earth water from the mixture, or a redistribution of the moisture content within the mixture.

When the aging is made at atmospheric tem- V perature, the mixture of the calcined diatomaceous earth, emulsification agent and detergent is allowed to stand for a substantial period, as. for example, several hours, and suitably about a day, before the mixture is packed. into the final container for shipment. Here, again, a redistribution of moisture between the several ingredients of the mixture may occur.

Curiously enough, free flowing is sometimes achieved also by the removal of grit from the calcined diatomaceous earth. This removal of grit is desirable, in addition, as a means of decreasing the tendency of the cleanser to scratch certain relatively soft surfaces to which it may be applied. Removal of the grit is accomplished in a convenient manner, for example, by suspending the comminuted calcined diatomaceous earth in :1

rapidly moving stream of air, forming this stream of air into a thin band and sharply deflecting the band fiatwise. The diatomaceous earth remaining in the deflected band is separated by conventional means. The separated earth is then ready for use.

It should be understood that the invention is not limited to any one explanation of the action of the aging of the cleansing mixture or the removal of grit from the calcined diatomaceous earth used in making the cleansing mixture, on the flowing properties of the final mixture. Also, it is not maintained that these factors would have equal effect on cleanser mixtures containing different ingredients or containing a different quality of diatomaceous earth. Y

Many variations may be made from the illustrative example that has been given, without departing from the scope of the invention.

Thus, the diatomaceous earth, calcined in comminuted form in the presence of a flux, may be substituted by diatomaceous earth calcined in comminuted form in the absence of a flux. In such cases, there may be used a comminuted calcined diatomaceous earth product made in a manner similar to that described in United States Patent 1,477,394 to Thatcher. However, such a material is not as desirable in cleansers for many purposes as the preferred form of diatomaceous earth, described above, that is, the product of the calcination of comminuted diatomaceous earth in the presence of a flux. For example, the diatomaceous earth calcined in the absence of a flux, as described in the aforesaid patent to Thatcher, has a weaker structure that gives to the product a softer and milder abrasive action. It will be understood that some of the reenforcing of the structure of the diatomaceous earth when the earth is calcined in the presence of a flux may be due to the action of the flux upon the diatomaceous earth. This particular reenforcing action due to the use of the flux is obviously not present in diatomaceous earth that has been calcined in the absence of a. flux. Also, the diatomaceous earth calcined in the absence of a flux may have a butt to pink color, suggestive of oxidized iron. For this reason cleansers made with such a product are not white.

When a very mild abrasive action is desired, the diatomaceous earth present in the cleanser may be an air-separated and almost impalpable grade. Such a grade may be made, for example, by calcining comminuted diatomaceous earth, either alone or in the presence of a flux, as described in the above mentioned patents to Thatcher and to Gil Calvert, Dem and Allies, commlnuting the cal abrasive in the cleanser. Another emulsiiication 'cined product, then making a suspension or it in agent that may be used, but that is not prei'erred, a rapidly moving stream of air, passing the susis saponin. The detergent should be a waterdust, and finally collecting a very fine fraction in neutralize acid materials, and/or saponiry rats a subsequent dust collecting apparatus, such as a and greases. Some detergents that have been stocking or bag house collector, in which the air used satisfactorily show a pH value in excess of content of the suspension filters out through 10, as, for example, approximately 11, when fabric and the very fine suspended solid particles tested in a solution of 0.1 part by weight or the 10 the Oden sedimentation test.

there are disadvantages when it is used for cerone that is commonly used in cleansing or poltain types of cleansers, due to the very mild abraishing compositions for the purpos roiwhich sive action of the unusually fine powder. On the improved composition 01' the present inventhe other hand, this extreme mildness of abrasive tion is intended.

To this impalpable or air-separated powder emulsification agent and/or detergent should be action is not objectionable when the product is It will be obvious that the properties of the 25 maceous earth products described, above. This phate, may make a cleanser that is somewhat a0 siliceous product and process of making the or detergent alone, but preferably with both same; Thus, the material may be made by comjointly.v

minuting natural diatomaceous earth, suitably Of the other materials that are conventionalin high grade material from an important Lompoc, cleansing and polishing compositions and that;

40 ing from the air stream the major part of the polishing compositions.

40 suspended particles, as by passage through a In making polishes, particularly those for series of cyclonic dust collectors, and then 001- smooth surfaces, such as that o! a lac uered aulecting the fine particles, as in a fabric dust coltomobile or brightly polished metal, there may lector, to give a very fine powder which in a made compositions having milder abrasive, typical preparation, showed less than 0.5% 01' emulsification and/or detergent properties than 45 particles of average size larger than 10 microns, the cleansers described above. ingredients ence of a small amount of a flux. Thus it may for example, calcined diatomaceous earth 5c minuted, as by passage through a high speed lacquered surface. In this case the composition 5 blower. The final result is a material containmay comprise a solvent for greases that is 1 i; 8 ing a large proportion of more or less spherular Solvent for the 1 1 fi h. a for example. 8 granules. In a typical preparation more than hydrocarbon such as gasoline, a wax, and/or a half of the material is finer than 30-mesh and llsht'rubbing oil. in addition to calcined diatocoarser than 150-mesh. maceous earth. Stearic acid may also be The diatomaceous earth products above densuch a composition. The calcined diatoma- 60 scribed and constituting the abrasive in the fin- 060115 a h d n my pol shing compositions ished composition are preferably so finely divided m y b i a ly h mp -lpable Powder described screening test, and should be insoluble in water Dlatomacwus earth alone does not constitute 65 7 tional cleanser ingredients. Thus, the emulsifi-- the invention, it lsintended that variations with as, for example, sodium soap or a potassium in the scope of the claims.

soap, or other material adapted to emulsii'y dirt What, I claim is: V

and remove it from a surface after the dirt has 1 1. A pulverulent composition of matter adapted been loosened therefrom by the action or the ioruse as a cleanser, weighing not substantially 75 more than 20 pounds to the cubic foot and comprising calcined diatomaceous earth particles retaining their diatomic structure not more than 2% of which are retained on a 30-mesh screen, and more than 5% of which are retained on a 325- mesh screen in a wet screening test. a powdered water-soluble soap and a detergent selected from the group consisting 01 sodium carbonate. sodium borate, sodium silicate and trisodium phosphate. the proportions by weight of the several ingredients of the said composition being of the order of the following: to parts of the diatomaceous earth, 2 to 10 parts of the soap, and 5 to 30 parts of the detergent.

2. A pulverulent cleanser composition weighing not substantially more than twenty pounds to the cubic foot and comprising 65 to 90 parts oi calcined comminuted grit-free diatomaceous earth, 2 to 10 parts of an emulsiilcation agent selected from the group consisting of an alkali metal soap and saponin and 5 to 30 parts of a detergent selected from the group consisting 01 sodium carbonate, sodium borate, sodium silicate, and trisodium phosphate.

3. A pulverulent cleanser composition weighing not substantially more than twenty pounds to the cubic foot and comprising 65 to 90 parts or flux-calcined comminuted grit-tree diatomaceous earth, 2 to 10 parts of an emulsiilcation agent selected from the group consisting of an alkali metal soap and saponin and 5 to 30 parts or a .prising 65 to detergent selected from the group consisting of sodium carbonate, sodium borate, sodium silicate. and trisodium phospha 4. A moisture-containing pulverulent cleanser composition weighing not substantially more than twenty pounds to the cubic foot and com- 90 parts of calcined comminuted grit-free diatomaceous earth, 2 to 10 parts of an emulsification agent selected from the group consisting of an alkali metalsoap and saponin and 5 to 30 parts oi a detergent selected from the group consisting 01! sodium carbonate, sodium borate. sodium silicate, and trisodium moisture in the composition being distributed therethroughout by ageing, whereby the composition is made tree-flowing.

5. A pulverulent cleanser composition weighing not substantially more than twenty pounds to the cubic foot and comprising 65 to 90 parts of calcined diatomaceous earth, 2 to 10 parts of an emulsification agent selected from the group consisting of an alkali metal soap and saponin and 5 to 30 parts of a detergent selected from the group consisting of sodium carbonate, sodium borate, sodium silicate, and trisodium phosphate, the diatomaceous earth being in the form of a granular product, more than half. of which is finer than 30-mesh and coarser than l50-mesh, resulting from calcining with a flux a very fine diatomaceous earth powder.

AR B. CUMMINS.

phosphate, the 

